Backside CMOS compatible BioFET with no plasma induced damage

ABSTRACT

The present disclosure provides a bio-field effect transistor (BioFET) device and methods of fabricating a BioFET and a BioFET device. The method includes forming a BioFET using one or more process steps compatible with or typical to a complementary metal-oxide-semiconductor (CMOS) process. The BioFET device includes a gate structure disposed on a first surface of a substrate and an interface layer formed on a second surface of the substrate. The substrate is thinned from the second surface to expose a channel region before forming the interface layer.

PRIORITY CLAIM

This application is a continuation of U.S. patent application Ser. No.14/799,453, filed on Jul. 14, 2015, now U.S. Pat. No. 9,709,525 issuedon Jul. 18, 2017 and entitled “Backside CMOS Compatible BioFET with NoPlasma Induced Damage” which is a continuation of U.S. patentapplication Ser. No. 14/281,100, filed on May 19, 2014, now U.S. Pat.No. 9,080,969 issued on Jul. 14, 2015 and entitled “Backside CMOSCompatible BioFET with No Plasma induced Damage” which is a divisionalof U.S. patent application Ser. No. 13/706,002, filed Dec. 5, 2012, nowU.S. Pat. No. 8,728,844 issued on May 20, 2014 and entitled “BacksideCMOS Compatible BioFET with No Plasma Induced Damage,” whichapplications are incorporated herein by reference.

BACKGROUND

Biosensors are devices for sensing and detecting biomolecules andoperate on the basis of electronic, electrochemical, optical, andmechanical detection principles. Biosensors that include transistors aresensors that electrically sense charges, photons, and mechanicalproperties of bio-entities or biomolecules. The detection can beperformed by detecting the bio-entities or biomolecules themselves, orthrough interaction and reaction between specified reactants andbio-entities/biomolecules. Such biosensors can be manufactured usingsemiconductor processes, can quickly convert electric signals, and canbe easily applied to integrated circuits (ICs) and MEMS.

BioFETs (biologically sensitive field-effect transistors, or bio-organicfield-effect transistors) are a type of biosensor that includes atransistor for electrically sensing biomolecules or bio-entities. WhileBioFETs are advantageous in many respects, challenges in theirfabrication and/or operation arise, for example, due to compatibilityissues between the semiconductor fabrication processes, the biologicalapplications, restrictions and/or limits on the semiconductorfabrication processes, integration of the electrical signals andbiological applications, and/or other challenges arising fromimplementing a large scale integration (LSI) process.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isemphasized that, in accordance with the standard practice in theindustry, various features are not drawn to scale. In fact, thedimensions of the various features may be arbitrarily increased orreduced for clarity of discussion.

FIGS. 1A-1C are flow charts of various embodiments of methods offabricating a BioFET device according to one or more aspects of thepresent disclosure.

FIGS. 2-4, 5A, 5B, 6A, 6B, 7A, 7B, 8A, 8B, 8C, 8D, 9A, 9B, and 9C arecross-sectional views of partially fabricated BioFET devices constructedaccording to one or more steps of the method of FIGS. 1A to 1C.

DETAILED DESCRIPTION

It is to be understood that the following disclosure provides manydifferent embodiments, or examples, for implementing different featuresof the invention. Specific examples of components and arrangements aredescribed below to simplify the present disclosure. These are, ofcourse, merely examples and are not intended to be limiting. Moreover,the formation of a first feature over or on a second feature in thedescription that follows may include embodiments in which the first andsecond features are formed in direct contact, and may also includeembodiments in which additional features may be formed interposing thefirst and second features, such that the first and second features maynot be in direct contact. Further still, references to relative termssuch as “top”, “front”, “bottom”, and “back” are used to provide arelative relationship between elements and are not intended to imply anyabsolute direction. Various features may be arbitrarily drawn indifferent scales for simplicity and clarity.

In a biological field-effect transistor (BioFET), the gate of ametal-oxide-semiconductor field-effect transistor (MOSFET), whichcontrols the conductance of the semiconductor between its source anddrain contacts, is replaced by a bio- or biochemical-compatible layer ora biofunctionalized layer of immobilized probe molecules that act assurface receptors. Essentially, a BioFET is a field-effect biosensorwith a semiconductor transducer. A decided advantage of BioFETs is theprospect of label-free operation. Specifically, BioFETs enable theavoidance of costly and time-consuming labeling operations such as thelabeling of an analyte with, for instance, fluorescent or radioactiveprobes.

A typical detection mechanism for BioFETs is the conductance modulationof the transducer due to the binding of a target biomolecule orbio-entity to a sensing surface or a receptor molecule immobilized onthe sensing surface of the BioFET. When the target biomolecule orbio-entity is bonded to the sensing surface or the immobilized receptor,the drain current of the BioFET is varied by the potential from thesensing surface. This change in the drain current can be measured andthe bonding of the receptor and the target biomolecule or bio-entity canbe identified. A great variety of biomolecules and bio-entities may beused to functionalize the sensing surface of the BioFET such as ions,enzymes, antibodies, ligands, receptors, peptides, oligonucleotides,cells of organs, organisms and pieces of tissue. For instance, to detectssDNA (single-stranded deoxyribonucleic acid), the sensing surface ofthe BioFET may be functionalized with immobilized complementary ssDNAstrands. Also, to detect various proteins such as tumor markers, thesensing surface of the BioFET may be functionalized with monoclonalantibodies.

One example of a biosensor has a sensing surface is a top of a floatinggate connected to the gate of the BioFET. The floating gate is connectedto the gate structure of the BioFET though a stack of metal interconnectlines and vias (or multi-layer interconnect, MLI). The various metallayers over the gate electrode can also contribute to damage by antennaeffect during the MLI formation process. In such a BioFET, thepotential-modulating reaction takes place at an outer surface of thefinal (top) metal layer or a dielectric surface formed on top of the MLIand is sensed indirectly by the BioFET. This embodiment may bedisadvantageous however, in that the sensitivity of the device isdecreased due to the presence of parasitic capacitances associated withthe MLI. As result a minimum sensing plate dimension is usuallyspecified so that a sufficiently detectable amount ofpotential-modulating reaction can take place. The minimum sensing platedimension in turn limits the BioFET density.

In another example, the biomolecules bind directly or through receptorson the gate or the gate dielectric of the BioFET. These “direct sensing”BioFETs directly senses the target biomolecules without the parasiticcapacitances associated with MLI. Its construction requires removal ofthe MLI material above the BioFET to form a sensing well and exposes thegate electrode or gate dielectric to the fluidic environment wherepotential-modulating surface reactions occur. These BioFETs are moresensitive than the floating gate types but are challenging to constructfor several reasons. The sensing well etched has a high aspect ratio,for example, 30 or greater, so it is usually performed with high energyplasma etch. The high-aspect ratio of the sensing well also limits theprofile of the etched sensing well. The high energy plasma etch candamage the gate electrode due to charge-induced damage. One attempt inreducing the aspect ratio of the sensing well to make the etch easierresults in limitation of the number of metal layers, down to one or twometal layers. The reduction in metal layers limits the interconnectrouting and integration options of the device, for example, the numberand type of circuits for controlling the BioFET. The process is alsovery sensitive to alignment, because misalignment may expose the metalsin the MLI surrounding sensing well or cause the sensing surface area tobe less than designed.

In yet another example, the biomolecules are placed close to the gatefrom a backside of the substrate. In this example, a sensing surface isformed on the backside of the transistor gate through backside of thesubstrate. This example avoids the difficulty of having to etch throughmultiple layers of interconnects and yet placing the biomolecules closeenough to the gate to have much higher sensitivity than the floatinggate biosensor. Illustrated in FIG. 1 is a method 100 of fabricating abio-organic field effect transistor (BioFET). The method 100 may includeforming a BioFET using one or more process steps compatible with ortypical to a complementary metal-oxide-semiconductor (CMOS) process. Itis understood that additional steps can be provided before, during, andafter the method 100, and some of the steps described below can bereplaced or eliminated, for additional embodiments of the method.Further, it is understood that the method 100 includes steps havingfeatures of a typical CMOS technology process flow and thus, are onlydescribed briefly herein.

The method 100 begins at block 102 where a substrate is provided. Thesubstrate may be a semiconductor substrate. The semiconductor substratemay be a silicon substrate. Alternatively, the substrate may compriseanother elementary semiconductor, such as germanium; a compoundsemiconductor including silicon carbide; an alloy semiconductorincluding silicon germanium; or combinations thereof. In someembodiments, the substrate is a semiconductor on insulator (SOI)substrate. As shown in FIG. 2, the SOI substrate may include a buriedoxide (BOX) layer 203 formed by a process such as separation byimplanted oxygen (SIMOX), and/or other suitable processes. The SOIsubstrate also includes a first semiconductor layer 201 and a secondsemiconductor layer 205 on either side of the BOX layer 203. A firstsurface or a first side 207 of the SOI substrate is the device sidewhere the gate of the FET is formed. A second surface or a second side209 of the SOI is the backside from which the substrate will be thinnedin a subsequent operation. The substrate may include doped regions, suchas p-wells and n-wells. In the present disclosure, a wafer is aworkpiece that includes a semiconductor substrate and various featuresformed in and over and attached to the semiconductor substrate. Thewafer may be in various stages of fabrication and is processed using theCMOS process. After the various stages of fabrication are completed, thewafer is separated into individual dies that are packaged into anintegrated chip.

Referring back to FIG. 1A, the method 100 then proceeds to block 104where a field effect transistor (FET) 210 is formed on the first side207 of the substrate. The FET 210 may include a gate structure(including dielectric 215 and electrode 217), a source region (211 or213), a drain region (211 or 213), and a channel region 219 interposingthe source and drain regions (211 and 213). The source, drain, and/orchannel region are formed on an active region of the semiconductorsubstrate. The active region is a part of the semiconductor layer 201.The FET 210 may be an n-type FET (nFET) or a p-type FET (pFET). Forexample, the source/drain regions may comprise n-type dopants or p-typedopants depending on the FET configuration. The gate structure mayinclude a gate dielectric layer 215, a gate electrode layer 217, and/orother suitable layers. In an embodiment, the gate electrode 217 ispolysilicon. Other exemplary gate electrodes include metal gateelectrodes including metal such as, Cu, W, Ti, Ta, Cr, Pt, Ag, Au;suitable metallic compounds like TiN, TaN, NiSi, CoSi; combinationsthereof; and/or other suitable conductive materials. In an embodiment,the gate dielectric is silicon oxide. Other exemplary gate dielectricsinclude silicon nitride, silicon oxynitride, a dielectric with a highdielectric constant (high k), and/or combinations thereof. Examples ofhigh k materials include hafnium silicate, hafnium oxide, zirconiumoxide, aluminum oxide, tantalum pentoxide, hafnium dioxide-alumina(HfO₂—Al₂O₃) alloy, or combinations thereof. The FET may be formed usingtypical CMOS processes such as, photolithography; ion implantation;diffusion; deposition including physical vapor deposition (PVD), metalevaporation or sputtering, chemical vapor deposition (CVD),plasma-enhanced chemical vapor deposition (PECVD), atmospheric pressurechemical vapor deposition (APCVD), low-pressure CVD (LPCVD), highdensity plasma CVD (HDPCVD), atomic layer CVD (ALCVD), spin on coating;etching including wet etching, dry etching, and plasma etching; and/orother suitable CMOS processes.

The method 100 may include forming additional layers over the PETincluding metal interconnect layers, dielectric layers, passivationlayers, bonding metal layers, and any other material layers typicallyformed in complete a semiconductor device. In FIG. 3, a layer 303 isdisposed over the FET between the FET and a carrier substrate 301. Thelayer 303 may include a multi-layer interconnect (MLI) structure. TheMLI structure may include conductive lines, conductive vias, and/orinterposing dielectric layers (e.g., interlayer dielectric (ILD)). TheMLI structure may provide physical and electrical connection to the FET210 at the source and drain 211 and 213 and at the gate electrode 217.The conductive lines may comprise copper, aluminum, tungsten, tantalum,titanium, nickel, cobalt, metal silicide, metal nitride, poly silicon,combinations thereof, and/or other materials possibly including one ormore layers or linings. The interposing or inter-layer dielectric layers(e.g., ILD layer(s)) may comprise silicon dioxide, fluorinated siliconglass (FGS), SILK (a product of Dow Chemical of Michigan), BLACK DIAMOND(a product of Applied Materials of Santa Clara, Calif.), and/or otherinsulating materials. The MLI may be formed by suitable processestypical in CMOS fabrication such as CVD, PVD, ALD, plating, spin-oncoating, and/or other processes.

If used, a carrier substrate 301 allows various subsequent operations onthe backside 209 of the semiconductor substrate without affecting thestructural integrity of the semiconductor substrate. The carriersubstrate 301 is attached to the semiconductor substrate by bonding. Insome embodiments, the carrier substrate is bonded to the last MLI layer.In an embodiment, the carrier substrate is bonded to a passivation layerformed on the MLI and/or ILD layers of the substrate. The carriersubstrate may be attached to the device substrate using fusion,diffusion, eutectic, and/or other suitable bonding methods. Exemplarycompositions for the carrier substrate include silicon, glass, andquartz. In some embodiments, the carrier substrate 301 may include otherfunctionality such as; interconnect features, bonding sites, definedcavities, and/or other suitable features. The carrier substrate may beremoved during subsequent processing (e.g., after thinning).

The method 100 then proceeds to block 106 where an active region of theFET is exposed from the backside of the substrate. Depending on the typeof substrate a number of methods may be used to expose the activeregion, which usually includes a channel region of the FET. According tovarious embodiments, the substrate is thinned from a backside. A firstthinning may be accomplished by grinding, wet etch, dry etch, plasmaetch and/or other suitable processes. In order to avoid plasma induceddamage (PID) with residual charge at the active region of the FET, anon-plasma etch is used in this operation or at least as the lastthinning step. Thus in some embodiments, a wet etch or a non-plasma dryetch is used to thin the entire substrate from the backside to theactive region. In other embodiments, a first thinning, which may includeplasma etch, is performed first to reduce the thickness of the substrateand a last etch operation uses a non-plasma etch to expose the activeregion at the backside of the substrate.

FIG. 1B is a flow chart showing block 105 of method 100 in accordancewith various embodiments of the present disclosure pertaining to whenthe substrate is a silicon-on-insulator (SOI) substrate. A SOI substratehas an intrinsic dielectric film, sometimes referred to as the buriedoxide (BOX) layer, between two semiconductor layers. The FET is formedin a first semiconductor layer, which is usually thinner than a secondsemiconductor layer on an opposite side of the intrinsic dielectricfilm. The second semiconductor layer is removed. In block 152 of FIG.1B, a semiconductor layer is removed from the SOI substrate. The removedsemiconductor layer is the semiconductor layer opposite from the FETsformed in block 104. The removal may be accomplished by mechanical orchemical means. For example, mechanical means includes polishing orgrinding, such as chemical mechanical polishing (CMP). A chemical meansincludes wet etch, such as HNA or TMAH or dry etch including plasma andnon-plasma etch. FIG. 4 shows a wafer 400 after a semiconductor layer205 from FIG. 3 is removed. The wafer 400 includes the intrinsicdielectric layer 203 and the carrier substrate 301 on either side of theFET 210.

In block 154 of FIG. 1B, the intrinsic dielectric film is thinned. Theintrinsic dielectric film may be a silicon oxide layer between about afew nanometers to several hundred nanometers. In some embodiments, theintrinsic dielectric layer is thinned by using wet etch, such asbuffered oxide etch (BOE), or a non-plasma dry etch. The intrinsicdielectric layer may be partially removed, such as the intrinsicdielectric layer 503 shown in FIG. 5A, or completely removed, such asthe embodiment shown in FIG. 5B. If the intrinsic dielectric layer ispartially removed, then a plasma-etch may be used for the thinning. Insome embodiments, the intrinsic dielectric layer is thinned to about2000 angstroms or less.

According to various embodiments, after a partial thinning of theintrinsic dielectric layer in block 154, a photoresist pattern is formedon a remaining portion of the intrinsic dielectric layer in block 154.The photoresist pattern protects some of the intrinsic dielectric layerfrom a subsequent non-plasma etch to expose an active region of the FETin block 158. The non-plasma etch may be a wet etch or a dry etch thatdoes not involve plasma. The non-plasma etch forms a trench 505 having abottom exposing the channel region 219 of the FET 210. A non-plasma etchis used to avoid plasma-induced damage at the exposed surface 509 of thechannel region 219. By thinning the intrinsic dielectric layer 203first, the trench 505 has a low aspect-ratio, for example, less thanabout 5 or even about 1 or less. The low aspect-ratio allows fineprofile control during the etch and avoid forming sharp corners that canimpede sensing film uniformity. In some embodiments, the sidewallprofile of the trench 505 is substantially straight.

According to some embodiments as shown in FIG. 5B, the intrinsicdielectric layer 203 is completely removed and the first semiconductorlayer 201 is exposed at surface 507. The complete removal may occur inone or more operations such as blocks 154 and 158 of FIG. 1B. However,the last operation which exposes the surface 507 cannot involve plasmaetch so as to avoid plasma-induced damage (PID) to surface 507.

If a photoresist pattern was formed in block 156, then in block 150 thephotoresist is removed. A PID-less photoresist removal process such asstripping and ozone ashing may be used. Because the exposed surface 509of the trench 505 and the exposed surface 507 of the first semiconductorlayer 201 are susceptible to plasma-induced damage (PID), some plasmaashing processes may not be used to remove the photoresist pattern.

Referring back to FIG. 1A, in block 108 an interface layer is formed inthe opening. FIG. 1C is flow chart showing block 108 of method 100 inaccordance with various embodiments of the present disclosure. In block182 of FIG. 1C, a sensing film is deposited over the wafer. The sensingfilm may be formed on the exposed surface 509 of the trench 505 and theexposed surface 507 of the first semiconductor layer 201. Also referredto herein as the interface layer, the sensing film is compatible (e.g.,friendly) for biomolecules or bio-entities binding. For example, thesensing film may provide a binding interface for biomolecules orbio-entities. The sensing film may include a dielectric material, aconductive material, and/or other suitable material for holding areceptor. Exemplary interface materials include high-k dielectric films,metals, metal oxides, dielectrics, and/or other suitable materials. As afurther example, exemplary sensing film materials include HfO₂, Ta₂O₅,Pt, Au, W, Ti, Al, Cu, oxides of such metals, SiO₂, Si₃N₄, Al₂O₃, TiO₂,TIN, ZrO₂, SnO, SnO₂; and/or other suitable materials. The sensing filmmay be formed using CMOS processes such as, for example, physical vapordeposition (PVD) (sputtering), chemical vapor deposition (CVD),plasma-enhanced chemical vapor deposition (PECVD), atmospheric pressurechemical vapor deposition (APCVD), low-pressure CVD (LPCVD), highdensity plasma CVD (HDPCVD), or atomic layer CVD (ALCVD). Inembodiments, the sensing film includes a plurality of layers.

FIGS. 6A and 6B shows a sensing film formed on the exposed surface 509of the trench 505 (FIG. 6A) and the exposed surface 507 of the firstsemiconductor layer 201 (FIG. 6B). In FIG. 6A, the sensing film isdeposited over the wafer on the field area above the remaining intrinsicdielectric layer 503 and sidewalls and bottom of trench 505. In FIG. 6B,the sensing film is deposited over the wafer over the entire surface 507of the semiconductor layer.

Referring back to FIG. 1C, in block 184, a photoresist pattern is formedover the sensing film to protect a portion of the sensing film. Theportion over the channel region of the FET is protected. Unprotectedportions of the sensing film is removed in an etch process in block 186.The etch process may involve any known etch process including plasmaetch, since the portion susceptible to PID is protected, FIGS. 7A and 7Bshows a sensing film 701 remaining on the respective surfaces. In FIG.7A, sensing film 701 is shown only at the bottom surface of trench 505;however, in some embodiments the sidewalls of the trench 505 may also becovered with sensing film 701. The sensing film 701 completely coversthe channel region 219 and partially covers the source and drain region211 and 213. The partial coverage of the source and drain region may beadjusted based on the FET design and area requirements for the sensingfilm 701. In FIG. 7B, the sensing film 701 completely covers the channelregion 219 and partially covers the source and drain region 211 and 213.In order to prevent unspecified binding of biomolecules on surfacesothers than a sensing film, a blocking layer or a passivating layer 702may be deposited. A passivating layer 702 may be silicon nitride,silicon oxide, or other solid-state dielectric layers. A blocking agent,which may be solid or liquid on which a bio-molecule cannot bind or haslow affinity, may be used in forming passivating layer 702. One exampleis hexamethyldisiloxane (HMDS). In another example, a protein such as aBovine Serum Albumin (BSA) is used as the blocking agent. The blockinglayer/passivating layer 702 may be thicker or thinner than the sensingfilm 701.

After etching and optionally adding a passivating or blocking agent, thephotoresist is removed in block 188 in a PID-free photoresist removalprocess. In some embodiments, the sensing film 601 is not patterned andetched and remains over the respective surfaces of the FET.

Referring back to FIG. 1A, in block 110 a film treatment or a receptorsuch as an enzyme, antibody, ligand, peptide, nucleotide, cell of anorgan, organism, or piece of tissue is provided or bound on an interfacelayer/sensing film for detection of a target biomolecule. For instance,to detect ssDNA (single-stranded deoxyribonucleic acid), the sensingfilm may be functionalized with immobilized complementary ssDNA strands.Also, to detect various proteins such as tumor markers, the sensing filmmay be functionalized with monoclonal antibodies. The receptors may be apart of self-assembled monolayer (SAM) of molecules. The SAM may havehead groups of silane groups, silyl groups, silanol groups, phosphonategroups, amine groups, thiol groups, alkyl groups, alkene groups, alkynegroups, azide groups, or expoxy groups. The receptors are attached tothe head groups of SAM.

In some embodiments, the sensing film is treated or modified with acoating or chemistry to affect its chemical functionality. For example,the sensing film may be treated to have a hydrophilic or hydrophobicsurface. In other examples, the sensing film may be modified to havecertain conductance or magnetic properties. The film treatment orreceptor may be produced by adsorption from solution either from a wettank or stamping and certain types of depositions such as sputtering orgaseous deposition. The receptors may be patterned, for example, byusing a micro-contact printing, dip-pen nanolithography, or byselectively removing receptors after attaching. When attached to thereceptors, biological material on the sensing film may be detected bythe BioFET because the electrical characteristics of the channel regionare altered by the presence of the biological material.

Referring back to FIG. 1A, in block 112 a microfluidic channel ormicrofluidic well is formed over the sensing film. Block 112 may beperformed before or after block 110 of method 100 of FIG. 1A dependingon the material used and type of treatment or receptor. For example,some receptors may be damaged during a microfluidic channel or wellformation structure. In some embodiments, the microfluidic channel orwell is deposited and shaped over the sensing well. FIGS. 8A/8B and9A/9B are cross section diagrams of microfluidic wells formed over thesensing film. FIG. 8A is an example where a trench 505 is formed oversensing film 601, FIG. 8B is an example where the intrinsic dielectriclayer was completely removed and no trench 505 was formed. In bothcases, a biocompatible material is deposited over the wafer to form asubstantially flat surface. In various examples, the biocompatiblematerial is a biocompatible photoresist. A photoresist may be usedbecause it is shaped easily by using photolithography without affectingthe sensing film surface. One example is epoxy-based negativephotoresist SU-8™. A photoresist may be transparent and a feature ofsuch microfluidic structure is that it can be observed externally duringoperation. The photoresist may be deposited using a spin-on tool,patterned by exposure, and developed to remove the wells as shown inFIGS. 9A and 9B. FIGS. 9A and 9B include microfluidic wells 901 formedin the biocompatible material 801. As shown, the microfluidic wells 901exposes the sensing film 601 (and any coating or receptors thereon) tothe biological fluid matter during operation.

In some embodiments, the biocompatible material is not a photoresist.The biocompatible material may be an epoxy, a silicone, for example,polydimethylsiloxane (PDMS), or other organic polymer such asPolyethylene glycol (PEG). The biocompatible material may be depositedin bulk and shaped on the BioFET, for example, by etching. Thebiocompatible material may also be deposited on the BioFET in a certainshape by molding, for example, by compression molding followed by curingor by injection molding through a mold. The biocompatible material 801is selected to have good adhesion with portions of the sensing film 601and the surface of the semiconductor layer between adjacent BioFETs.

In still other embodiments, a microfluidic channel or well is formedseparately from the BioFET and attached in a separate operation. FIGS.8C and 8D are cross section diagrams that include a pre-formedmicrofluidic structure 803 that is then attached to the wafer over thesensing film and passivating/blocking layer 804. The microfluidicstructure 803 may be formed separately and individually attached to thewafer before the BioFET device is diced. The microfluidic structures 803may also be formed as a package substrate that maps to the BioFET deviceon the wafer one to one to allow a wafer level formation of the BioFETdevice. The microfluidic structures 803 may be attached by anodicbonding or adhesive bonding. The microfluidic structures 803 may includeinlets/outlets, wells, channels, and reservoirs operable to hold afluid. The microfluidic structures 803 may further include material thathelps to direct the flow biological matter and conduct analysis. Forexample, the microfluidic structures 803 may include micropumps andvalves and magnetic material or ferromagnetic material formagnetophoresis, metals for electrophoresis, or particular dielectricmaterial for dielectrophoresis.

The microfluidic structure 803 may be fabricated and/or connected orbonded to the BioFET device outside of a CMOS process, for example, themicrofluidic structure may be fabricated and/or connected to the deviceusing processes that are not typical of standard CMOS fabrication. Insome embodiments a second entity, separate from the entity fabricatingthe transistors, may connect the microfluidic structure to the BioFETdevice. A separate formation of the microfluidic structure allows agreater variety of material to be used and larger process window when itis not formed on easily-damaged BioFET. Uniformity of the BioFET surfacefor attaching the microfluidic structure may become more important asthe photoresist-based microfluidic structure would be able to betteraccommodate surface variations.

In still other embodiments, the microfluidic structure may be formedusing a combination of operations. FIG. 9C is a cross section diagram ofa BioFET having a two part microfluidic structure: a microfluidic wellstructure 1001 formed over the sensing film by deposition andpatterning, and microfluidic channels structures 1003 attached to themicrofluidic well structure 1001.

One aspect of the present disclosure pertains to a method ofmanufacturing a biological field-effect transistor (BioFET) thatincludes forming a FET device on a semiconductor substrate, wherein theFET device includes a gate structure formed on a first surface of thesemiconductor substrate and a channel region; exposing the channelregion from a second surface of the semiconductor substrate, wherein asurface of the channel region is exposed by a non-plasma etch; andforming a sensing film on the channel region of the second surface ofthe semiconductor substrate in the opening. The method may also includethinning the semiconductor substrate from a second surface; or forming areceptor on the sensing film, wherein the receptor is selected from thegroup consisting of enzymes, antibodies, ligands, peptides, nucleotides,self-assembled molecules. The sensing film may be Si₃N₄, Al₂O₃, TiO₂,HfO₂, Ta₂O₅, SnO, SnO₂, BaxSr_(1-x)TiO₃ or combinations of these.

Another aspect of the present disclosure pertains to a method ofmanufacturing a BioFET on an SOI substrate. The method includes forminga FET device on a SOI semiconductor substrate, wherein the FET deviceincludes a gate structure formed on a first surface of the semiconductorsubstrate and a channel region in the semiconductor substrate below thegate structure; attaching the first surface of the semiconductorsubstrate to a carrier substrate; exposing the channel region from asecond surface of the semiconductor substrate by removing a portion ofthe semiconductor substrate; forming an sensing film on the channelregion of the second surface of the semiconductor substrate in theopening; and, forming a microfluidic channel or microfluidic well overthe sensing film.

In yet another aspect, the present disclosure pertains to a devicehaving a carrier substrate, a first BioFET device attached to thecarrier substrate, and a microfluidic channel or microfluidic wellstructure disposed over a sensing film on the first BioFET device. Thefirst BioFET device includes a gate structure on a first side of asemiconductor substrate; a source region and a drain region in thesemiconductor substrate adjacent to the gate structure; a channel regioninterposing the source and drain regions and underlying the gatestructure; and, a sensing film directly on and covering at least aportion of the channel region on a second side of the semiconductorsubstrate.

In describing one or more of these embodiments, the present disclosuremay offer several advantages over prior art devices. In the discussionof the advantages or benefits that follows it should be noted that thesebenefits and/or results may be present is some embodiments, but are notrequired in every embodiment. Further, it is understood that differentembodiments disclosed herein offer different features and advantages,and that various changes, substitutions and alterations may be madewithout departing from the spirit and scope of the present disclosure.

What is claimed is:
 1. A method of using a biological field-effecttransistor (BioFET) device, comprising: providing the bioFET device, thebioFET device having a gate structure formed on a first surface of asemiconductor layer, a channel region in the semiconductor layer belowthe gate structure, source and drain regions in the semiconductor layeron opposite sides of the channel region, wherein the gate structure isaligned between the source and drain regions, and a sensing film isdirectly on the source, drain, and channel regions on a second surfaceof the semiconductor layer, the second surface being opposite from thefirst surface; and disposing a film treatment or a receptor on thesensing film.
 2. The method of claim 1, wherein the disposing comprisesbinding ssDNA strands to the sensing film.
 3. The method of claim 1,wherein the disposing comprises binding monoclonal antibodies to thesensing film.
 4. The method of claim 1, wherein the disposing comprisesbinding a self-assembled monolayer (SAM) to the sensing film.
 5. Themethod of claim 4, wherein the SAM includes head groups chosen from thegroup consisting of silane groups, amine groups, thiol groups, alkylgroups, alkene groups, alkyne groups, azido groups, and expoxy groups.6. The method of claim 1, wherein the disposing comprises disposing afilm treatment on the sensing film configured to change a hydrophobicityof a surface of the sensing film.
 7. The method of claim 1, wherein thedisposing comprises patterning the receptor on the sensing film using atleast one of micro-contact printing, dip-pen nanolithography, orselective removal of the receptor.
 8. A method of using a biologicalfield-effect transistor (BioFET) device, comprising: providing thebioFET device, the bioFET device having a gate structure formed on afirst surface of a channel region in a semiconductor layer, source anddrain regions in the semiconductor layer on opposite sides of thechannel region, wherein the gate structure is aligned between the sourceand drain regions, and a sensing film is formed directly on the sourceand drain regions and on a second surface of the channel region, thesecond surface being opposite from the first surface; and disposing afilm treatment or a receptor on the sensing film.
 9. The method of claim8, wherein the disposing comprises binding ssDNA strands to the sensingfilm.
 10. The method of claim 8, wherein the disposing comprises bindingmonoclonal antibodies to the sensing film.
 11. The method of claim 8,wherein the disposing comprises binding a self-assembled monolayer (SAM)to the sensing film.
 12. The method of claim 11, wherein the SAMincludes head groups chosen from the group consisting of silane groups,amine groups, thiol groups, alkyl groups, alkene groups, alkyne groups,azido groups, and expoxy groups.
 13. The method of claim 8, wherein thedisposing comprises disposing a film treatment on the sensing filmconfigured to change a hydrophobicity of a surface of the sensing film.14. The method of claim 8, wherein the disposing comprises patterningthe receptor on the sensing film using at least one of micro-contactprinting, dip-pen nanolithography, or selective removal of the receptor.15. A method of using a biological field-effect transistor (BioFET)device, comprising: providing the bioFET device, the bioFET devicehaving a gate structure formed over a channel region in a semiconductorlayer, source and drain regions in the semiconductor layer on oppositesides of the channel region, wherein the gate structure is alignedbetween the source and drain regions, and a sensing film is formeddirectly on the source, drain, and channel regions and beneath the gatestructure, and disposing a film treatment or a receptor on the sensingfilm.
 16. The method of claim 15, wherein the disposing comprisesbinding ssDNA strands to the sensing film.
 17. The method of claim 15,wherein the disposing comprises binding monoclonal antibodies to thesensing film.
 18. The method of claim 15, wherein the disposingcomprises binding a self-assembled monolayer (SAM) to the sensing film.19. The method of claim 18, wherein the SAM includes head groups chosenfrom the group consisting of silane groups, amine groups, thiol groups,alkyl groups, alkene groups, alkyne groups, azido groups, and expoxygroups.
 20. The method of claim 15, wherein the disposing comprisespatterning the receptor on the sensing film using at least one ofmicro-contact printing, dip-pen nanolithography, or selective removal ofthe receptor.